Index of Lean Ireland courses – onsite

Join us on this learning journey through Lean Tools and their Application. You will discover the meaning and uses of 5S workplace organization, identifying the 7 wastes and A3 problem solving. You will receive simple and effective tips for improving processes, increasing customer satisfaction and lowering costs.

This practical onsite workshop takes place over one day and involves practical exercise, review of case studies and an interactive quiz at the end. The workshop is designed to be a practical and fun way to learn about lean. Following the onsite workshop, candidates have to option of working in a team to complete a simple case study A3 structured process improvement.

A Lean Practitioner, Level 1, certificate is awarded to those who have full attendance and work in a team to complete and present a case study A3 project.

Lean Ireland tutors are certified lean six sigma black belts with several years’ experience in facilitating lean implementation in a wide variety of sectors.

See full course outline S01 Lean Fundamentals

The Toyota A3 8-step problem solving process is highly interactive and collaborative in nature. The objective is to enable the problem solver and team to ‘find a problem, solve a problem and prevent a problem from coming back’. The 8 steps are written up or drawn on an A3 size sheet of paper. This encourages brevity and facilitates sharing of information amongst all stakeholders. This onsite 2-day workshop will enable all participating problem-solvers to approach problems with confidence, and to use a standard systematic process to resolve those problems. The two workshop days are run back-to-back. Participants who complete an organization
based A3 team project will receive a Lean Ireland Lean Practitioner Level 1 certificate.

See full course outline Toyota A3 8-Step Problem Solving

Lean and six sigma are approaches to process management that enable all personnel to work in collaborative teams. Lean six sigma teams are responsible for reviewing and revising processes that deliver value to customers. Process problems are error proofed; process steps are standardized and variation in process outcomes is reduced. Customer satisfaction grows & costs fall.

A Lean Six Sigma White Belt has completed a basic level of training in teamwork and process problem solving techniques. White Belts are expected to work in teams and resolve low level local problems on an on-going basis. To enable retention of concepts and tools, the course uses a simple process problem to illustrate the full six sigma define, measure, analyse, Improve and control (DMAIC) project cycle.

See full course outline Lean six sigma white belt

The ability to analyse and control performance is an essential requirement for the effective management of processes that deliver value to customers. Process control involves observation, data collection, tabulation, graphical representation and both qualitative and quantitative analysis.

This two-day workshop aims to give participants a solid grounding in data collection, graphing and basic analysis techniques in Minitab. Participants will be introduced to the Minitab statistical software application, and will learn when and where to use analysis techniques in order to aid decision making. It will enable participants to develop standards with regards to data collection, analysis and reporting appropriate for their processes.

See full course outline Process Analysis & Control with Minitab

Lean six sigma problem solving processes are highly interactive and collaborative in nature. The objective is to enable the problem solver and team to ‘find a problem, solve a problem and prevent a problem from coming back’. The 5 key problem-solving steps are Define, Measure, Analyse, Improve and Control (DMAIC). The DMAIC steps in a CLSSYB project are planned and written up on an A3 sized template. This encourages brevity and facilitates sharing of information among all stakeholders.

During this lean six sigma certified course, you participate in the workshops as a team member and learn how to use lean six sigma tools to resolve process issues on a small-scope A3 project. Your knowledge builds in a step wise fashion over two days and you will be supported and encouraged throughout your learning journey.

This course is designed to enable all participants, regardless of sector or previous education, to
certify to CLSSYB level.

See full course outline S05 Certified Lean Six Sigma Yellow Belt

Lean thinking is an approach to employee management, process management and workplace organization that increases market share through superior customer satisfaction. At the same time costs are reduced as employees seek to continuously make shorter, simpler and safer the processes that deliver value to customers. However, identifying the practical steps that will bring about this change to voluntary continuous improvement is not always easy, and sometimes counter intuitive. This workshop introduces key lean concepts and provides simple and effective tips for increasing customer satisfaction whilst lowering costs.

This course is offered as a live and lively in-company active workshop, where the participating team transforms a simulated manufacturing organisation from loss making to profitability, using the lean approach. The course runs with a minimum of 10 and maximum of 16 candidates.

Lean Ireland tutors are certified lean six sigma black belts with several years’ experience in facilitating lean implementation in a wide variety of sectors.

See full course outline S06 Lean Immersion workshop

Lean six sigma enables all employees to work in collaborative teams to improve process performance and increase customer satisfaction. A Green Belt (GB) project leader is capable of leading a cross-functional team through a series of formal project and problem solving steps. GB projects are short-projects (c. 10 – 20 weeks) that result in customer satisfaction and cost savings or additional revenue for the organization.

On this course you will learn that lean and six sigma are about teamwork, process management and customer service. It is designed to enable all participants, regardless of sector or previous education, to certify as a Lean Six Sigma Green Belt (CLSSGB). The course consists of a series of facilitated onsite all-day workshops with case studies, interactive exercises, assignments and project work. Your knowledge builds in a step-wise fashion and you will be supported and encouraged throughout your learning journey.

The software application used is Minitab.

See full course outline Certified lean six sigma green belt (CLSSGB)

Lean six sigma enables all employees to work in collaborative teams to improve process performance and increase customer satisfaction. A Green Belt (GB) project leader is capable of leading a crossfunctional team through a series of formal project and problem-solving steps. GB projects are shortprojects (c. 8 – 20 weeks) that result in customer satisfaction and cost savings or additional revenue for the organization.

On this course you will learn that lean and six sigma are about teamwork, process management and customer service. It is designed to enable all participants, regardless of sector or previous education, to certify as a Lean Six Sigma Green Belt (CLSSGB). The course consists of a series of interactive workshops, individual and team exercises, graded assignments and project work. Your knowledge builds in a stepwise fashion, and you will be supported and encouraged throughout your learning
journey. The software application used is MS Excel.

See full course outline S07X Certified Lean Six Sigma Green Belt (Excel)

DOE is an approach to process design and analysis that identifies which input factors in a process (e.g. temp, pressure, time, altitude, colour, material type) have most influence on the process outputs, and enables the selection of optimal settings for these inputs in order to optimize process outputs. This interactive workshop introduces DOE to development chemists, engineers, managers, and technicians. The focus is on the practical application of this essential product and process development tool.

The course covers factor selection, experiment design and execution, and visual statistical analysis and on how to use JMP effectively to design and run experiments. It is a foundation course in DOE, designed for a broad audience. Tuition in more advanced DOE techniques is also available for those who would like to become subject matter experts.

See full course outline Design of Experiments (DOE) – JMP

DOE is an approach to process design and analysis that identifies which input factors in a process (e.g. temp, pressure, time, altitude, colour, material type) have most influence on the process outputs, and enables the selection of optimal settings for these inputs in order to optimize process outputs. This interactive workshop introduces DOE to development chemists, engineers, managers, and technicians. The focus is on the practical application of this essential product and process development tool.

The course covers factor selection, experiment design and execution, and visual statistical analysis and on how to use Minitab effectively to design and run experiments. It is a foundation course in DOE, designed for a broad audience. Tuition in more advanced DOE techniques is also available for those who would like to become subject matter experts.

See full course outline Design of Experiments (DOE) – Minitab

Lean six sigma enables all employees to work in collaborative teams to improve process performance and increase customer satisfaction. The black belt (BB) is a full-time six sigma programme member who has responsibility for selecting & prioritising projects, leading projects, deploying project learnings and training and mentoring green belts. The BB is trained in advanced project management and statistical analysis tools. The BB is expected to contribute between €250K and €1M to the company’s operating profit each year by undertaking process improvement projects that lead to enhanced customer satisfaction.

The course consists of a series of 20 all-day onsite workshops, interactive exercises, assignments and project work. Your knowledge builds in a step wise fashion and you will be supported and encouraged throughout your learning journey. This course is offered on an in-company basis only i.e. all candidates are from the one organisation. The course content is customised to meet the organisation’s need, at no extra cost. All Lean Ireland tutors are certified Lean Six Sigma black belts with several years’ experience in facilitating workshops in a wide variety of sectors.

The software application used is Minitab. The course is also offered in SAS JMP if required.

See full course outline Certified Lean Six Sigma Black Belt (CLSSBB)

Value stream mapping (VSM) is a high-level diagnostic tool that provides a foundation for a continuous improvement journey. VSM enables a management team to take a systems approach to increasing customer satisfaction and decreasing the cost of operations along the entire product and service value stream. VSM enables an organisation to set its strategic and tactical direction over a number of years, as well as select and scope the projects that will deliver change.

A VSM workshop is facilitated for each major product or service range on an annual basis during which “one year’s worth” of projects is identified to further enhance customer service and process performance. This course introduces participants to VSM, using paper and Post It methods to document the process and identify system disconnects.

This course is offered on an in-company basis only i.e. all candidates are from the one organization for a minimum of 8 and maximum of 15 candidates.

See full course outline Value Stream Mapping (VSM) 

SPC involves the collection and analysis of data in order to understand process behaviour, manage variation and control the process outcome. This two-day workshop provides an introduction to basic and popular SPC techniques, using Minitab statistical software.

Lean Ireland consultants are experienced in the training and coaching of personnel, from a wide variety of sectors, in the use of Minitab for the statistical measurement, analysis and control of process problems.

See full course outline S11M Statistical Process Control (SPC) with Minitab

The Toyota 8-step problem solving process is highly interactive and collaborative in nature. The objective is to enable the problem solver and team to ‘find a problem, solve a problem and prevent a problem from coming back’. The 8 steps are written up or drawn on an A3 size sheet of paper. This encourages brevity and facilitates sharing of information among all stakeholders.

During this lean course, you participate in the workshops as a team member and learn how to use lean tools to resolve process issues on a small-scope A3 project. Your knowledge builds in a step wise fashion over two days and you will be supported and encouraged throughout your learning journey.

This course is designed to enable all participants, regardless of sector or previous education, to certify
as a Lean Yellow Belt (CLYB).

See full course outline S14 Certified Lean Yellow Belt

Developed by Shigeo Shingo, consultant with the Toyota Motor Company, SMED is a method for reducing waste in a manufacturing process. SMED provides guidelines for reducing the time to tear down and set up a machine, necessary steps to convert from manufacturing the current product to running the next product. SMED is also used for shortening clean down and line clearance times.

SMED or quick changeover is key to increasing available production time, reducing production lot sizes and thereby improving flow.

This course enables you to identify and implement improvements to the set-up/changeover process on a machine. Participants will learn how through run a full SMED exercise using appropriate lean tools such as video, process mapping, spaghetti mapping, error proofing and standard work. The course is facilitated over two full days onsite. Ideally, you will commence a SMED exercise on site at the start of the course, and report on SMED success as an assignment following course completion.

See full course outline Quick change over (SMED) 

We are human, therefore we make mistakes or errors. This is a simple universal truth. Error proofing is the process of anticipating, preventing, & detecting errors which adversely affect customers & result in waste. True error proofing methods are located close to the potential site of error, act as 100% prevention mechanisms, and are cheap by comparison with the cost of making the error.

During this one-day course, participants will learn why we make errors, common error types, error detection mechanisms and a variety of interventions that will enable us to prevent the error occurring.

This course will enable all participating problem-solvers to approach problems with confidence, and to use a standardised systematic process to resolve those problems or lessen their impact on the organisation. The objective is to enable the participants to find an error, correct an error, and prevent an error from recurring.

See full course outline Human Error Proofing

The objective of TPM is to maintain plant or equipment in good condition and at the same time optimise process output. This is achieved through collaboration between maintenance, production and engineering resources. The overall effect is a reduction is stoppages, an increase in process yield, and a reduction in cost i.e. no Breakdowns, no Small Stops or Slow Running, no Defects and no Accidents.

Operations personnel are more in control of their working environment, as their knowledge of how to manage machines is deepened. Maintenance personnel are freed from routine tasks to engage in more creative and value adding work e.g. tool design.

The Lean Ireland TPM training course is an interactive onsite workshop designed to empower operations, maintenance, engineering and quality personnel in the workplace. It is tailored to meet clients’ needs. Course content is adapted to suit the sector and equipment type used in the process value stream.

See full course outline Total Productive Maintenance (TPM) 

Business process mapping is an interactive paper and marker exercise that enables a cross functional team to map all activities associated with a process. Once the ‘as is’ process is mapped the team identifies all wasteful, error prone and non-value adding activities. The objective of this 1-day workshop is to arrive at an agreed set of activities that will be addressed over the coming months to (a) provide a better service to customers, (b) make the process easier to operate and (c) make
the process cheaper to operate.

The process will be mapped using a combination of flipchart, 1M deep strong paper roll, and Post Its. These are provided by Lean Ireland. A room approximately 6 metres of free wall or window space is required to complete the exercise.

See full course outline S19 Process Mapping

A clean well organised workplace is a delight for the team in any organisation. It enhances safety, enables a smooth workflow and reduces the probability of errors and stoppages. the results is an ongoing increase in productivity and creativity.

Lean Ireland 5S workshops are hands on, immersive and rewarding.

See full course outlline S20 5S Workplace organisation

Join us on this learning journey through structured problem solving using Lean Fundamentals. You will receive simple and effective tips for improving processes, increasing customer satisfaction and lowering costs. The online lean course is made up of a series of short interactive webinars. Each webinar provides
an introduction to the topic, some case studies and has an interactive quiz at the end. They are designed to be a practical and fun way to learn about lean. The two 4-hour webinars are run at typically one week apart.

The course content can be tailored to suit your organization, with relevant case studies, quizzes and data sets for assignments. Lean Ireland online lean course designers and facilitators are certified lean six sigma black belts with several years’ experience in facilitating lean implementation in a wide variety of sectors. If you’d like more details on customization, please call us or send an email.

See full course outline Root Cause Analysis: Fundamentals

Very often we collect large data sets, however lack the ability to truly interrogate the data in a way that aids decision making and process improvement. The ability to scientifically assess and root cause process problems is a key asset for the serious process analyst.

This advanced 2-day workshop introduces a number of statistical tools that enable the identification of the root cause of process problems. It is designed to enable participants to identify patterns, anomalies and relationships in data sets. The software application used is Minitab.

See full course outline S22 Root Cause Analysis Advanced

Developed by reliability engineers in the 1950’s, FMEA is a team-based risk assessment approach that strives to identify all possible failure modes of a product or process, and to eliminate or mitigate the impact of those failure modes. It involves the establishment of a table of risks in priority order, and the execution of tasks and projects to (i) eliminate the risk, or (ii) reduce the probability or the risk occurring, or (iii) reduce the impact of the outcome of the risk if it does occur. FMEA is most effective when done at the design phase of a product or process.

The Lean Ireland workshop is facilitated with a cross functional team of product or process experts (and occasionally an outside pair of eyes) working on an actual organisation product or process.

See full course outline Failure Modes and Effects Analysis (FMEA)